Professional Documents
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OD1651
EDITION
8
WELDING OPERATIONS, I
WELDING OPERATIONS, I
SUBCOURSE NO. OD1651
United States Army Combined Arms support Command
Fort Lee, Virginia 23801-1809
6 Credit Hours
GENERAL
The purpose of this course is to introduce
involved in metal-arc welding operations.
the
basic
requirements
hours
are
awarded
for
successful
completion
of
this
ii
TABLE OF CONTENTS
Section
Page
TITLE..........................................................
TABLE OF CONTENTS..............................................
iii
Lesson 1:
61
103
105
REFERENCES.....................................................
107
iii
LESSON 1
ELECTRODES CLASSIFICATION AND
INTENDED USES; AUTOMOTIVE WELDING PROCESSES,
MATERIALS, AND IDENTIFICATION PROCESSES;
METHODS OF DESTRUCTIVE AND NONDESTRUCTIVE
TESTING OF WELDS AND TROUBLESHOOTING PROCEDURES;
TYPES AND TECHNIQUES OF JOINT DESIGN; AND
THE THEORY, PRINCIPLES, AND PROCEDURES OF
WELDING ARMOR PLATE
TASK 1.
CONDITIONS
Within a self-study environment and given the subcourse text, without
assistance.
STANDARDS
Within three hours
REFERENCES
No supplementary references are needed for this task.
1.
Introduction
as
c.
Classification of Electrodes.
system
for
stainless
steel
d. Types of Electrodes.
There are three different types of
electrodes.
They are: bare, thinly coated, and shielded-arc or
heavy-coated electrodes.
(1) Bare Electrodes.
Bare electrodes are made of wire
compositions required for specific applications and have no
coatings other than those required in wire drawing.
These wire
drawing coatings have some slight stabilizing effect on the arc,
but are otherwise of no consequence.
Bare electrodes are used
for welding manganese alloy steel, and other purposes where a
coated electrode is not required or is undesirable.
A
diagrammatic sketch of the transfer of metal across the arc of a
bare electrode is shown in figure 1, view A, on the following
page.
(2) Thinly Coated Electrodes.
(a) Thinly coated electrodes are made of a wire of a definite
composition.
A thin coating is applied on the surface of the
electrode by washing, dipping, brushing, spraying, tumbling, or
wiping to improve the stability and characteristics of the arc
stream.
They are listed under the E45 series in the electrode
identification system described in paragraph 2c, beginning on
page 3.
(b) The coating on these types of electrodes generally serves
the functions described below:
1 It dissolves or reduces impurities, such as oxides, sulfur,
and phosphorous, and thus keeps impurities out of the weld
deposit.
2 It reduces the adhesive force between the molten metal and
the end of the electrode, or changes the surface tension of the
molten metal so that the globules of metal leaving the end of the
electrode are smaller and more frequent, thus making the flow of
molten metal more uniform and continuous.
3 It increases the stability of the arc by introducing
materials readily ionized into the arc stream.
That is, the
coating fuels the arc by providing smaller particles when the
electric charge occurs.
FIGURE 1.
FIGURE 2.
metal (at the end of the electrode) to break up into fine small
particles.
(5) The coatings contain ingredients such as silicates that,
when melted, form a slag over the melted weld and base metal.
Since the slag solidifies at a relatively slow rate, it holds the
heat and allows the underlying metal to cool and solidify slowly.
This slow solidification of the metal precludes the trapping of
gases within the weld and permits solid impurities to float to
the surface.
Slow cooling also has an annealing effect on the
weld deposit.
(6) The physical characteristics of the weld deposit are
modified by incorporating alloying materials in the electrode
coating.
Also, the fluxing action of the slag will produce a
weld of a better quality and permit welding at higher speeds.
(7) The coating insulates the sides of the electrode so that
the arc, at the end of the electrode, is concentrated into a
confined area.
This facilitates welding in a deep "U" or "V"
groove.
(8) The coating produces a cup, cone, or sheath, as shown in
figure 2, view A, on page 7, at the tip of the electrode, which
acts as a shield, concentrates and directs the arc, reduces heat
losses, and increases the temperature at the end of the
electrode.
f.
that the opposite is true and the greater heat is produced on the
negative side.
Electrode coatings affect the heat conditions
differently, depending on their composition.
One type of heavy
coating may provide the most desirable heat balance with straight
polarity, while another type of coating on the same electrode may
provide a more desirable heat balance with reverse polarity.
(3) Reverse polarity is used in the welding of nonferrous
metals such as aluminum, bronze, monel, and nickel.
Reverse
polarity is also used with some types of electrodes for making
vertical and overhead welds.
(4) The proper polarity for a given electrode can be recognized
when attempting a weld by the sharp, cracking sound of the arc.
The wrong polarity will cause the arc to emit a hissing sound and
the welding bead will be difficult to control.
g.
10
11
content.
of
12
13
FIGURE 3.
14
slowly
by
placing
an
15
16
FIGURE 4.
17
operation of components.
All protrusions should be ground down
flush before reinforcing plates are applied.
Reinforcement
plates should be approximately the same thickness as the frame
section and the width sufficient to bring the weld flush with the
top and bottom sections of the channel. It should be noted that
the welded ends of the plates produce heat affected areas of
decreased strength across the back and legs of the channel.
(b) Front Axles.
Front axles are made of heat treated alloy
drop forgings.
Repairs by welding should not be made on these
axles except as a temporary measure under extreme emergency
conditions.
(c) Rear Axle Housings.
These components are made of welded
pressed steel or malleable cast iron or cast steel. The pressed
steel and cast steel housings can be arc welded.
The malleable
iron housings should be repaired by brazing; although, they can
be welded if extreme precautions are maintained. Castings should
be kept clean in the vicinity of the weld.
(d) Drive Shafts.
Drive shafts are usually made of medium
carbon steel seamless tubing and are readily weldable by either
arc or gas welding.
(e) Machined Alloy Steel Parts.
These type parts such as
crankshafts, connecting rods, gears, and axle drive shafts are
not generally repaired by welding because the heat of welding
will impair the metal qualities produced by previous heat
treatment.
(f) Radiators. Radiators can be repaired with an oxyacetylene
welding torch containing a proper tip, common 50-50 solder, and
flux. The oxyacetylene flame should be adjusted to give a slight
carburizing mixture.
The areas around the leaks in the copper
tubes should be thoroughly cleaned, preferably with a 5 percent
solution of hydrochloric acid, and tinned before the joint is
made in order to ensure a tight joint. For leaks between copper
and cast iron, the surface of the iron should be pickled before
the repair is made. Pickling the surface of the iron is done by
applying a 5 percent hydrochloric acid solution to it at the
joint and heating it until thoroughly cleaned.
18
19
FIGURE 5.
BUTT JOINTS.
20
FIGURE 6.
21
22
FIGURE 7.
c. Types of Welds.
The type of weld used will determine the
manner of seam, joint, or surface preparation. A listing of the
different welds used is provided in the following subparagraphs.
(1) Groove Weld (figure 8 on the following page).
These are
welds that are made in a groove between two members to be joined.
In this position, the axis of the weld lies approximately in a
horizontal plane and the face of the weld lies approximately in a
vertical plane.
(2) Surfacing Weld (figure 9 on page 25).
This type weld is
composed of one or more string or weave beads deposited on an
unbroken surface to obtain desired properties or dimensions.
23
FIGURE 8.
24
GROOVE WELDS.
FIGURE 9.
(3) Plug Weld (figure 9). This is a circular weld made through
one member of a lap or tee joint joining that one member with the
other. This type weld may or may not be made through a hole in
the first member.
(4) Slot Weld (figure 9).
This weld is made in an elongated
hole in one member of a lap joint or tee joint joining that
member to the surface of the other member that is exposed through
the hole.
(5) Fillet Weld. This type weld is shown in figure 6, view L,
on page 21.
It is a triangular cross section weld joining two
surfaces at right angles to each other.
(6) Flash Weld (figure 10 on the following page). This weld is
made by the application of pressure over the entire area of
abutting surfaces after heating them is completed.
25
FIGURE 10.
26
Welding Techniques
a. General.
In metal-arc welding a number of separate factors
are responsible for the transfer of molten filler metal and
molten slag to the base metal.
Among these are the techniques
employed in the actual process of welding.
The following
subparagraphs serve to describe these techniques.
b.
27
FIGURE 11.
28
WELDING POSITIONS.
TABLE 1.
29
(1) The following are two methods used for starting the arc:
(1) the striking or brushing method shown in figure 12, view A,
and (2) the tapping method shown in figure 12, view B. In both
methods, the arc is formed by short circuiting the welding
current between the electrode and the work surface. The surge of
high current causes both the end of the electrode and a small
spot on the base metal beneath the electrode to melt instantly.
30
FIGURE 12.
31
WARNING
If the electrode becomes frozen to the base metal
during the process of starting the arc, all work to
free the electrode when the current is on should be
done with the face shield pulled down over the eyes.
(5) Some electrodes, known as contact electrodes, are normally
struck by holding them in contact with the work.
These
electrodes are used mostly by private industry rather by the Army
in the field.
(6) Two procedures, described in the following subparagraphs,
are used to break the arc.
(a) In manual welding, when the electrode is changed and the
weld is to be continued from the crater, the arc is shortened and
the electrode moved quickly sideways out of the crater. When the
arc is re-established it is started at the forward or cold end of
the crater, moved backward over the crater, then forward again to
continue the weld. The crater is also filled by this procedure.
(b) In semiautomatic welding, where filling or partial filling
of the crater is required, the electrode is held stationary for a
time sufficient to fill the crater and then is gradually
withdrawn until the arc breaks.
32
d.
(1) Maladjustments.
Table 3 provides a listing of the effects on
welding as a result of improper current, voltage, and welding speed
control.
TABLE 3.
EFFECTS OF MALADJUSTMENTS OF
WELDING CURRENT VOLTAGE AND
SPEED ON THE BEAD
CHARACTERISTICS.
33
FIGURE 13.
34
ARC CHARACTERISTICS,
AND DEFECTS.
(1) When the arc is struck, metal particles melt off the end of
the electrode and are deposited in the molten puddle on the
surface of the work.
As the electrode melts it becomes shorter
and causes the arc to increase in length unless the electrode is
fed down to the work as fast as the end is melted off and
deposited.
Before moving the electrode forward, the arc should
be held at the starting point for a short time to ensure good
fusion and to allow the bead to build up slightly.
When the
welding machine is adjusted for proper current and polarity, good
bead welds can be made by maintaining a short arc and welding in
a straight line at a constant speed.
35
FIGURE 14.
36
37
FIGURE 15.
38
FIGURE 16.
39
(c) When using any of the weaving motions, the electrode should
be oscillated or moved uniformly from side to side with slight
hesitation at the end of each oscillation and, as in bead
welding, the electrode should be inclined 5 to 15 degrees in the
direction of welding.
If the weaving motion is not properly
performed, undercutting will occur at the joint as shown in
figure 16, view C, on the previous page. Excessive welding speed
will also cause undercutting and poor fusion at the edges of the
weave bead.
(2) Butt Joints in Flat Position with Backup Strips (figure 16,
view D).
(a) Backup or backing strips are used when welding 3/16 inch
plate or heavier to obtain complete fusion at the root of the
weld and to provide better control of the arc and the weld metal.
The edge of the plates to be welded are prepared in the same
manner as required for welding without backing strips.
The
backing strips, 1 inch wide and 3/16 inch thick for plates up to
3/8 inch thick, 1 1/2 inch side, and 1/4 inch thick for plates
over 1/8 inch thick, are tack welded to the base of the joint.
The backing strip will act as a cushion for the first bead or
layer deposited in the joint.
(b) The joint should be completed by adding additional layers
of metal using the procedures prescribed in paragraphs 5e, on
pages 35 and 36.
(c) After the joint is completed, the backup strip may be
washed off or cut away with a cutting torch and, if necessary, a
sealing bead may then be applied along the root of the joint.
(3) Plug and Slot Joints (figure 17 on the following page).
(a) Plug and slot welds, shown in figure 17, views A and B, are
used to join two overlapping plates, by depositing and filling a
hole or slot in the upper plate.
Slot welds are used in butt
straps to join face hardened armor plate edges from the back or
soft side. They are also used to fill up holes in plates and to
join two overlapping plates where it is impossible to join them
by any other method.
40
FIGURE 17.
41
42
FIGURE 18.
FILLET WELDING.
43
FIGURE 19.
44
(2) Lap Joint (figure 19, views B and C, on the previous page).
(a) In making lap joints, two overlapping plates are tack
welded in place and a fillet weld in the horizontal position is
deposited along the joint.
(b) The procedure for making this weld is similar to that used
for making fillet welds in tee joints.
The electrode should be
held so as to form an angle approximately 30 degrees from the
vertical and tilted 15 degrees in the direction of welding. The
position of the electrode in relation to the plates is shown in
figure 19, view C. The weaving notion is the same as that used
for tee joints, except that the pause at the edge of the top
plate is sufficiently long to ensure good fusion and no under
cut.
Lap the joint by depositing a series of overlapping beads
on top of each other.
(c) In making lap joints on plates of different thicknesses as
shown in figure 20, view A, on the following page, the electrode
is held so as to form an angle of 20 to 30 degrees from the
vertical.
Care must be taken not to overheat or undercut the
thinner plate edge. Also, the arc must be controlled to wash up
the molten metal to the edge of this plate.
h.
45
FIGURE 20.
46
47
FIGURE 21.
48
FIGURE 22.
49
more than 15 degrees above the horizontal for proper molten metal
control. The arc should be held short to obtain good fusion and
penetration.
(b) When welding tee joints in the vertical position, the joint
should be started at the bottom and welded upward and the
electrode should be moved in a triangular weaving motion as shown
in figure 22, view A, on the previous page.
A slight pause in
the weave, at the points indicated, will improve the sidewall
penetration and provide good fusion at the root of the joint.
1 If the weld metal should overheat, the electrode should
quickly shifted away from the crater without breaking the arc
shown in figure 22, view B. This will permit the molten metal
solidify without running downward.
The electrode should
returned immediately to the crater of the weld in order
maintain the desired size of the weld.
be
as
to
be
to
Position
Welding
(figure
23
on
the
following
50
FIGURE 23.
51
down or sag on the plate. If the arc is too long, the difficulty
in transferring metal from the electrode to the base metal is
increased and large globules of molten metal will drop from the
electrode and the base metal.
This action can be prevented by
first shortening and then lengthening the arc at intervals. Care
must be taken not to carry too large a pool of molten metal in
the weld.
(a) When bead welding, the electrode should be held at an angle
of 90 degrees to the base metal as shown in figure 23, view A, on
the previous page. The electrode may be tilted approximately 15
degrees in the direction of welding as shown in figure 23, view B
to provide a better view of the arc and crater of the weld.
(b) Weave beads can be made in the overhead position by using
the motion illustrated in figure 23, view C. A rapid motion is
necessary at the end of each semicircular weave in order to
control the molten metal deposit.
Excessive weaving should be
avoided because this will cause overheating of the weld deposit
and the formation of a large pool of metal which will be hard to
control.
(2) Butt Joints.
(a) The plates should be prepared for butt welding in the
overhead position in the same manner as that required in the flat
position, and the most satisfactory results are obtained if
backup strips are used. If the plates are beveled with a feather
edge and no backup strip is used, the weld will tend to burn
through repeatedly unless extreme care is taken by the operator.
(b) For overhead butt welding, bead rather than weave welds are
preferred.
Each bead should be cleaned and the rough areas
chipped out before the following pass is deposited.
The first
pass should be made with the electrode held at 90 degrees to the
plate as shown in figure 23, view D.
(c) The position of the electrode and the order to be followed
in depositing beads on 1/4 and 1/2 inch plates are illustrated in
figure 23, views E and F.
(d) Fairly small diameter electrodes should be used to assist
in holding a short arc and developing a good penetration at the
root of the
52
FIGURE 24.
OVERHEAD POSITION
FILLET WELDING.
53
(b) Fillet welds for either tee or lap joints, on heavy plate
in the overhead position, require several passes to make the
joint. The first pass is a string bead with no weaving motion of
the electrode.
The second, third, and fourth passes are made
with a slight circular motion of the electrode with its top
tilted about 15 degrees in the direction of welding as shown in
figure 24, view C, on the previous page.
This motion of the
electrode permits greater control and better distribution of the
weld metal being deposited. All slag and oxides must be removed
from the surface of each pass by chipping or wire-brushing before
applying additional beads.
6.
a. General.
All of the ferrous metals used on Army ground
equipment can be successfully electric arc welded, provided
normal care is used and the correct procedure followed.
The
following subparagraphs provide the welding techniques for four
of the most common types of ferrous metals found on this
equipment.
The description of welding techniques for other
ferrous metals may be found in TM 9-237.
b.
High-Carbon Steels.
(1) General.
High-carbon steels include those that have a
carbon content exceeding 0.45 percent.
Because of the high
carbon content and the heat treatment usually given to these
steels, their basic properties are to some degree impaired by arc
welding.
Preheating the metal between 500 to 800 Fahrenheit
before welding and stress relieving it by heating from 1200 to
1450 with slow cooling should be used to avoid hardness and
brittleness in the fusion zone.
Either mild-steel or stainless
steel electrodes can be used to weld these steels.
(2) Welding Technique.
(a) The welding heat should be adjusted to provide good fusion
at the sidewalls and root of the joint without excessive
penetration. High welding heat will cause excessive penetration
and puddling which in turn can cause large areas in the fusion
zone to become hard and brittle. Control of the welding heat and
excessive penetration can be accomplished by depositing the weld
metal in small string beads. The area of these hard zones in the
54
Tool Steels.
(1) General.
Steels in this group have a carbon content
ranging from 0.80 to 1.5 percent. They are rarely welded by arc
welding because of the excessive hardness produced in the fusion
zone of the base metal.
If arc welding must be done, either
mild-steel or stainless-steel electrodes can be used.
(2) Welding Technique.
(a) If the parts to be welded are small, they should be
annealed or softened before welding.
The edges should then be
preheated up to 1,000, depending on the carbon content and
thickness of the plate, and the welding done with either a mildsteel or high-strength electrode.
55
56
Cast Iron.
(1) General.
Gray cast iron has low ductility; therefore, it
will neither expand, nor stretch, to any considerable extent
before breaking or cracking.
Because of this characteristic,
preheating is necessary when cast iron is welded by the
oxyacetylene welding process. However, it can be welded with the
metal arc without preheating if the welding heat is carefully
controlled.
This can be accomplished by welding only short
lengths of the joint and allowing these sections to cool.
By
this procedure, the heat of welding is confined to a small area
and the danger of cracking the casting is eliminated.
Large
castings with complicated sections, such as motor blocks, can be
welded without dismantling or preheating.
Special electrodes
designed for this purpose are usually desirable.
(2) Welding Techniques.
(a) Cast iron can be satisfactorily welded with a coated steel
electrode, but this method should be used as an emergency measure
only. When using a steel electrode the contraction of the
57
steel weld metal, the carbon picked up from the cast iron by the
weld metal, and the hardness of the weld metal caused by rapid
cooling must be considered.
Steel shrinks more than cast iron
when cooled from a molten to a solid state and, when a steel
electrode is used, this uneven shrinkage will cause strains at
the joint after welding.
When a large quantity of filler metal
is applied to the joint, the cast iron may crack just back of the
line of fusion unless preventive steps are taken.
To overcome
these difficulties, the prepared joint should be welded by
depositing the weld in short string beads, 3/4 to 1/4 inch long,
made intermittently and, in some cases, by the step-back or skipwelding procedure. To avoid hard spots, the arc should be struck
in the V and not on the surface of the base metal.
Each short
length of weld metal applied to the joint should be lightly
peened, while hot, with a small ballpeen hammer and allowed to
cool before additional weld metal is applied. The peening action
forges the metal and relieves metal strain during cooling.
(b) The electrodes used should be 1/8 inch in diameter so as to
prevent generating excessive welding heat. The welding should be
done with reverse polarity.
Weaving of the electrode should be
held to a minimum.
Each metal deposit should be thoroughly
cleaned before additional metal is deposited.
(c) Cast iron electrodes are used where subsequent machining of
the welded joint is required.
Stainless steel electrodes are
used when machining of the weld is not required.
The procedure
for making welds with these electrodes is the same as that
outlined for welding with mild-steel electrodes. Stainless steel
electrodes provide excellent fusion between the filler and base
metals; however, great care must be taken not to overheat the
base metal.
Overheating the base metal will cause cracking of
the base metal alongside the weld metal.
The reason for this
cracking of the base metal is that stainless steel expands and
contracts approximately 50 percent more than mild steel in equal
changes of temperature.
7.
58
adhered to.
The following subparagraphs describe the welding
techniques used only for aluminum. Aluminum and aluminum alloys
can be satisfactorily welded by metal-arc, carbon-arc, and other
arc-welding processes. The principal advantage of using the arcwelding processes is that a highly concentrated heating zone is
obtained with the arc and, for this reason, excessive expansion
and distortion of the metal is prevented. With the exception of
the welding rod used, the welding techniques used for other
nonferrous metals, namely titanium, nickel, bronze, brass,
magnesium, and monel, are the same as those used for aluminum.
b.
Welding Techniques.
59
8.
Conclusion
60
LESSON 1
ELECTRODES CLASSIFICATION AND
INTENDED USES; AUTOMOTIVE WELDING PROCESSES,
MATERIALS, AND IDENTIFICATION PROCESSES;
METHODS OF DESTRUCTIVE AND NONDESTRUCTIVE
TESTING OF WELDS AND TROUBLESHOOTING PROCEDURES;
TYPES AND TECHNIQUES OF JOINT DESIGN; AND
THE THEORY, PRINCIPLES, AND PROCEDURES OF
WELDING ARMOR PLATE
TASK 2.
CONDITIONS
Within a self-study environment and given the subcourse text, without
assistance.
STANDARDS
Within two hours
REFERENCES
No supplementary references are needed for this task.
1.
Introduction
61
2.
General
selection
of
welding
materials
and
repair
of
safety
hazards
fire
and
safety
hazard
62
3.
(1) General.
There are two types of armor that are used on
combat vehicles: homogeneous, which can be cast or rolled, and
face hardened, which is rolled.
It is essential that the armor
plate be specifically identified before any welding or cutting
operations are performed. This is important because the welding
procedures for each type of armor are distinctly different and
are not interchangeable.
(2) Homogeneous Armor Plate. Homogeneous armor is heat treated
through its entire thickness to develop good shock or impact
resisting properties. This type of armor is uniform in hardness,
composition, and structure throughout and can be welded on either
side. Aluminum armor plate is in the homogeneous class. Welding
procedures for aluminum armor plate are the same as for gas
metal-arc welding, which are discussed in the inert gas welding
operation subcourse.
(3) Face Hardened Armor Plate.
Face hardened armor plate has
an extremely hard surface layer which is obtained by carburizing.
(Carburizing is the process of combining carbon with another
alloy
63
64
(1) General.
The procedure for cutting this type of armor is
essentially the same as that required for homogeneous armor.
However, every precaution should be taken to keep as much heat as
possible away from the hard face side of the plate. This is done
by cutting from the soft side of the armor plate. Cutting from
the soft side limits the extent of heating and consequent
softening of the hard face side.
(2) Cutting with the Oxygen Torch.
(a) The general practice used for oxygen torch cutting
applied for cutting armor plate, but the tip size,
oxygen, and preheating gas temperatures should be kept
minimum,
consistent
with
good
quality
cuts,
to
overheating.
(b) Stainless steel is a nonoxidizing metal.
cutting stainless steel type welds
can be
cutting
at the
prevent
Therefore, when
65
FIGURE 25.
66
FIGURE 26.
67
68
a. General.
Before welding damaged armor plate, the type of
armor must first be identified.
This identification can be
accomplished in the field by one of the methods described in
paragraph 2c on page 63.
Homogeneous armor plate can be
satisfactorily welded using the electric arc welding process and
18-8 stainless steel heavy coated electrodes with reverse
polarity. Armored vehicles that have been exposed to conditions
of extreme cold should not be welded until the base metal has
been preheated sufficiently to bring the temperature of the base
metal in the zone of welding up to no less than 100 F. At this
temperature, the metal will be noticeably warm to the touch. If
this preheat is not applied, cracking will occur in the deposited
weld metal.
b.
Procedure.
69
FIGURE 27.
70
WELDING CRACKS IN
HOMOGENEOUS ARMOR.
bead welding are shown on figure 28. For narrow root openings, a
3/16 inch stainless steel electrode without coating can be tack
welded in place as shown in figure 28, view A.
Welding bead
numbers 1 through 4 are then deposited sequentially. To ensure a
sound weld, remove all slag and oxides from the joint before
depositing beads 3 and 4. If a mild steel rod or strip, as shown
in figure 28, view B, the back side of the backing rod or strip
should be chipped out after beads 1 and 2 are deposited to
minimize dilution in beads 3 and 4. The use of a stainless steel
strip as a backing for root beads in a wide root opening is shown
as view C of figure 28. An alternate
FIGURE 28.
71
72
FIGURE 29.
73
FIGURE 30.
74
FIGURE 31.
shrinkage
75
FIGURE 32.
76
77
FIGURE 33.
78
FIGURE 34.
EMERGENCY REPAIRS.
79
FIGURE 35.
80
FIGURE 36.
81
FIGURE 37.
82
a.
General.
(1) The face side of face hardened armor is extremely hard and
brittle.
Cracks on this type armor plate can be welded
satisfactorily from the soft side. These cracks can be repaired
by using 18-8 stainless steel reverse polarity heavy coated
electrodes. Special precautions, however, must be taken to avoid
distorting and excessively heating the armor plate.
Distortion
and excessive heat place stress on the base metal causing the
plate face to crack.
(2) Satisfactory methods for welding this type of armor makes
use of the butt strap and butt welding techniques, shown in
figures 39 and 40 on pages 85 and 86. The dimensions of the butt
strap depend on the thickness of the armor.
Butt strap
dimensions for armor up to one inch thick are
83
FIGURE 38.
84
FIGURE 39.
85
FIGURE 40.
86
FIGURE 41.
BUTT STRAP.
87
FIGURE 42.
88
CORNER JOINT IN
ARMOR PLATE.
FIGURE 43.
89
FIGURE 44.
90
91
7.
joints
are
Testing of Welds
Performance Tests.
92
Physical Tests.
(1) General.
These types of tests are designed to check the
skill of the welder, the quality of the weld metal, and the
strength of the welded joint. Some of these tests, such as the
free bend and nick break tests, are destructive. In these tests,
the specimen is tested until it fails in order that the desired
information can be gained.
Other physical tests, such as the
hydrostatic and magnetic particle tests, are not destructive.
Then there are simple physical tests, such as the appearance,
fracture, and grinding tests, that can be performed with tools
found in a field maintenance company shop. These simple physical
tests are described in the following subparagraph.
The
destructive and nondestructive type tests are described in the
succeeding subparagraphs.
(2) Simple Physical Tests.
(a) Appearance Test.
This is a nondestructive test.
In this
type test, a visual examination is made of the weld to check for
such defects as brittleness, cracks, craters, undercut, overlap
and slag inclusions. All these defects are unacceptable and the
joint must be reconstructed and rewelded.
(b) Fracture Test.
This is a destructive test.
To perform
this test, a cross section specimen must be cut off from the
welded metal. The specimen is then fractured to expose the weld.
The welded zone is then visually examined to check for unevenness
of the weld metal grain, cracks, craters, and inadequate
penetration of the weld into the base metal.
(c) Grinding Test.
This is a nondestructive test.
It is
particularly applicable to seal bead welds made for waterproofing
and sealing cracks in
93
94
FIGURE 45.
95
96
FIGURE 46.
97
FIGURE 47.
98
99
9.
Troubleshooting Welds.
100
a backup bar if possible. Chip or cut out the back of the joint
and deposit a bead of weld metal at this point.
Step 2. Check the size of the electrode being used.
Do not
expect excessive penetration from an electrode.
Use small
diameter electrodes in a narrow welding groove to permit reaching
the bottom of the groove.
Step 3. Check the welding current setting.
welding current to obtain proper penetration.
Use
sufficient
101
parts
parts
10. Conclusion
This task served to describe the theory, principles, and
procedures of welding armor plate; the methods of destructive and
nondestructive testing of welds, and the troubleshooting of welds
pertaining to electric arc welding. This task completes the text
material of this lesson.
The next task consists of a practical
exercise which you are required to complete by providing the
answers to the questions.
102
PRACTICAL EXERCISE
Instructions
This exercise is provided to test your progress in learning the
materials in the subcourse.
Please answer the questions that
follow.
You may check your answers from the page that follows
the questions.
1. List two of the seven factors that must be considered in
selecting electrodes.
2. What are the three groups into which metal-arc electrodes may
be grouped and classified?
3. The American Welding Society has formulated a number series
for the identification of electrodes.
a. What
signify?
does
the
letter
at
the
beginning
of
this
number
better
10. Of the four general positions used for welding, which is most
difficult to weld in?
103
11. What are the two types of armor plate used on Army combat
vehicles?
12. What type of armor plate may be repaired from both sides?
13. What is one of the three simple tests that can be performed
in a maintenance company shop for testing welds?
14. What is one of the three nondestructive tests that is used
for testing welds?
15. What is the first step in troubleshooting a weld with poor
fusion?
104
LESSON 1.
1.
a.
b.
c.
d.
e.
f.
g.
Specific properties
Type of base metal
Position of the weld
Type of current available
Current polarity available
Dimensions of the section to be welded
The type of fit permitted by the work
2.
a.
b.
c.
Bare
Thinly coated
Shielded-arc or heavy coated
3.
a.
b.
4.
a.
b.
c.
the
5.
6.
7.
8.
a.
b.
c.
d.
e.
9.
Butt joint
Corner joint
Edge joint
Lap joint
Tee joint
Appearance test
Fracture test
Grinding test
105
14. a.
b.
c.
106
REFERENCES
107
REFERENCES
The following documents were
developing this subcourse:
TM 9-237
108
used
as
resource
materials
in